Life cycle energy and greenhouse gas emissions for an ethanol production process based on blue-green algae

Ethanol can be produced via an intracellular photosynthetic process in cyanobacteria (blue-green algae), excreted through the cell walls, collected from closed photobioreactors as a dilute ethanol-in-water solution, and purified to fuel grade ethanol. This sequence forms the basis for a biofuel production process that is currently being examined for its commercial potential. In this paper, we calculate the life cycle energy and greenhouse gas emissions for three different system scenarios for this proposed ethanol production process, using process simulations and thermodynamic calculations. The energy required for ethanol separation increases rapidly for low initial concentrations of ethanol, and, unlike other biofuel systems, there is little waste biomass available to provide process heat and electricity to offset those energy requirements. The ethanol purification process is a major consumer of energy and a significant contributor to the carbon footprint. With a lead scenario based on a natural-gas-fueled combined heat and power system to provide process electricity and extra heat and conservative assumptions around the ethanol separation process, the net life cycle energy consumption, excluding photosynthesis, ranges from 0.55 MJ/MJ(EtOH) down to 0.20 MJ/ MJ(EtOH), and the net life cycle greenhouse gas emissions range from 29.8 g CO₂e/MJ(EtOH) down to 12.3 g CO₂e/MJ(EtOH) for initial ethanol concentrations from 0.5 wt % to 5 wt %. In comparison to gasoline, these predicted values represent 67% and 87% reductions in the carbon footprint for this ethanol fuel on a energy equivalent basis. Energy consumption and greenhouse gas emissions can be further reduced via employment of higher efficiency heat exchangers in ethanol purification and/ or with use of solar thermal for some of the process heat.